Aluminum automotive drive shaft

Abstract

A method for producing aluminum drive shafts from molten aluminum alloy using a continuous caster to cast the alloy into a slab. The method comprises providing a molten aluminum alloy consisting essentially of 0.2 to 0.8 wt. % Si, 0.05 to 0.4 wt. % Cu, 0.45 to 1.2 wt. % Mg, 0.04 to 0.35 wt. % Cr, 0.7 wt. % max. Fe, 0.15 wt. % max. Mn, 0.25 wt. % max. Zn, 0.15 wt. % max. Ti, the remainder aluminum, incidental elements and impurities and providing a continuous caster such as a belt caster for continuously casting the molten aluminum alloy. The molten aluminum alloy is cast into a slab which is rolled into a sheet product. After solution heat treatment, the sheet product is formed into a tube having a seam which is welded to provide a seam welded tube. The seam welded tube is placed in a forming die and hydroformed to form the drive shaft.

Description

BACKGROUND OF THE INVENTION[0001]This invention relates to automotive drive shafts and more particularly, it relates to a method of using a continuous caster such as a belt caster for casting aluminum alloy into a slab which is rolled into sheet for forming into automotive drive shafts. Further, the invention relates to improved tubular members used for making such drive shafts and an improved method of making the tubular members.[0002]To improve fuel economy, there is an intense effort to lightweight automobiles and trucks by replacing steel components with aluminum components. However, sometimes the fabrication practice for the aluminum members can become so expensive as to greatly diminish the benefit of the weight savings of the aluminum components. Thus, there is a great need for improved aluminum fabrication practices which minimize the cost of producing the aluminum components. This is particularly true in the fabrication of automotive drive shafts. Drive shafts are used to t...

AI Technical Summary

Benefits of technology

"The invention provides an improved process for producing aluminum sheet products with consistent levels of formability. The process involves continuously casting a slab and rolling it into a sheet product suitable for forming into various parts such as drive shaft tubular members. The process also involves using a continuous caster to cast the alloy and a forming die for hydroforming the sheet product into the desired shape. The resulting drive shaft tubular members have good levels of formability and can be used in automotive applications. The invention also provides a specific alloy composition that can be used for the process."

Problems solved by technology

However, sometimes the fabrication practice for the aluminum members can become so expensive as to greatly diminish the benefit of the weight savings of the aluminum components.

However, in many instances DC cast ingot or billet material has a higher total conversion cost associated with it when compared to continuous casting of molten aluminum into slab utilizing twin belt or twin roll casters.

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